Electrical System

EXIT
etrical s y s t e m 54
EXIT
54 Equipment, i n s t r u m e n t s
Job No.
Battery
Battery test, service, maintenance .................. ........................... 54-005
A.Testing battery .........................................................
B.Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C. Handling battery when laying up vehicle ......... ...............................
D. Batteries with overfill protection ................ ...............................
Ground connecting points

Designation and layout of ground connecting points ................................... 100
Centralelectrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
A.Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Associatron of harness couplings to couplrng fields ..............................
C. Layout of screw connections .................. .............................
D. Layoutoffusesand relays ...............................................
E. Layout of relays on relay holder ............... ..............................
F. Combination relay ..................... . ..............................
Central electncs, remove and rnstall ................. .............................. 150
Electric connections of special equipment ............... ........................... 152
Instruments
Removal and rnstallation of instrument cluster ......... .............................. 250
Removal and Installation of indicating instrument ....... ........................... 251
Removal and installation of tachometer ...... ... .... .............................. 253
Checking indicator for economic driving (ECONOMY) ................................... 255
Function of immersron tube transmitter for fuel gauge .................................. 256
Testingfuelgauge .................................... .................. 257
Removal and Installation of clock/revolution counter ............. .................. 258
Testing electric outside temperature rndrcator ........................................ 261
Renewing lamp carrier with acoustic turn signal checkup ......... .................... 262
Checking windshield washer water level indicator ................................. 264
Operation of auxiliary instruments models 20 1.034 ............................... 266
Removal and installation of auxiliary instruments ....... .............................. 267
Sun visor with rllumrnated mirror ............................. .................. 395
Warning device for safety belt, ignition key, light @ ... ........................ 410
54/l
EXIT
54 Cruise control
Job No.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................... 54-500

Testing with adapter .............................. ...... ....................... 504
Testing with coding plug .................................. ....................... 506
Removal and installatron of actuator ......................... ...................... 541
A.Engine102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B.Engine103 .................................. . . . . . . . . . . . . . . . . . . . . . . .
C. Engines 601,602.911 ..............................
D.Engine602.961 ................................... ... ....................
Removal and installation of switch cruise controVTempomat ....... ................... 545
A. 2nd version starting approx. middle of April 1984 .........
B. 1st version model 201 up to approx. middle of April 1984 ... ........................
Removal and installation of transmitter ....................... ..................... 550
Adjusting connectrng rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....................... 561
C. Engine 102 with injection system except engine 102.983 ...
D.Engine102.983 ................. ............. . . ..
E.Engine 103 . . . . . . . . . . . . . . . . . . . . . ............. . . ..
F.Engrne601 . . . . . . . . . . . . . . . . . . . . . ............. . . ..
G.Engine 602.961 . . . . . . . . . . . . . . . . . ............. . . . ........................
Removal and installation of control unrt ...................... ....................... 565
Removal and installation of coding plug ....................... .................... 566
Removal and installatron of switch on clutch pedal ....... ...... ....................... 575
Layout of plug connections .............................. ....................... 579
5412
EXIT
54-005 Battery test, service and maintenance
A. Testing battery
Visual checkup for external leaks
Check acid level should reach up to mark.

If the acid level must be corrected On batteries on which the
by adding distilled water, recharge fluid level cannot be seen,
battery afterwards up to gassing. keep adding distilled water
until water is no longer
flowing off at overfill guard.
Battery state of charge Climatic condition Density at 20 OC Procedure

( kg/dm3 1
charged normal 1.28)

tropics 1.23) -
half charged normal 1.20 recharging

tropics 1.16 required
discharged normal 1.12 recharge

tropics 1.08 immediately
*) Tolerance * 0.01 kg/dm3
Test acid density in individual cells Acid density should be the same in all
ccl Is.
Example for defective batteries
a) Acid density in one cell deviates noticeable in downward

directions.
I-1,28 1 I,202 1,283. 1,284 l,lfis 1,286

+ Condition: Short-circuit in cell 5
b) Acid density deviates in two adjacent cells (e.g. 2 and 3)

clearly from remaining measuring values in downward direction.
Condition: Leak in cell wall between

- 1 2 3
1,28 1,16 1,16 1,2e' 1,28' 1.2: cell 2 and 3.
.
The leaking cell wall and the connector
operate as a conductor through which
the cells are discharged.
54.5-005/l
EXIT
Testing battery under load This test is possible only at uniform

(perform only if no fault has been acid density of cells and an acid
found during previous tests) density of at least 1.24 kg/dm3
Capacity Ah 55 62 72 90 92
Load current
A 165 190 265 270 280
(approx. 3-times capacity) )
V 9 10
Minimum voltage21
after 10 s at acid density
kg/dm3 1.24 1.28
1) At 72 Ah higher.
2) After 10 seconds the test voltage should attain a constant value. Slight deviations have no influence.
If the voltage drops considerably or completely collapses, the battery is defective.
6. Charging battery
Batteries can be charged with DC only. For charging, the battery is separated from electric circuit of vehicle
and connected to a charger:
Positive pole (+I of battery to positive pole of charger,
negative pole (-1 of battery to negative pole of charger.
The charging current (A) should amount to 10 % of battery capacity, e.g. at 55 Ah a charging current of 5.5 A.
For recharging, higher currents may be employed up to start of gassing (2.4 V/cell).
Charge until acid density and charging voltage are no longer increasing within 2 hours. Note that the measuring
value of the acid density changes by 0.01 per 15 OC temperature difference. If, for example, an acid temperature
of 34 OC is measured, the simultaneously measured acid density should be increased by 0.01 to obtain the value
referenced to 20 OC.
54.5-00512 F 2
EXIT
C. Handling battery when laying up vehicle
Prerequisite: Battery state of charge in order

Acid density min. 1.26 kg/dm3 (tropics 1.21 kg/dm3 1
1. Disconnect negative terminal of battery.
This will prevent discharging by rest potential consumers or time clock.
2. Recharge battery after 3 months (acid density 1.28 kg/dm3, tropics 1.23 kg/dm3 1.
Attention!
Never leave battery standing about in discharged condition, since otherwise the plates will sulfate.
Sulfated plates will cause initial damage to battery and will lead to early breakdown.
Antifreeze in charged condition
normal tropics
charged - 65 - 40
half-charged in OC - 30 - 13
discharged - 12 - 6
54.5-005/3
EXIT
D. Batteries with overfill protection
These batteries are provided with rubber diaphragm

elements and vent ducts in filter neck of battery
cover. This will prevent an increase of fluid level
above max. mark when the batteries are filled.
When refilling with distilled water, make sure that

the diaphragm is not punched through or removed.
Also make sure that on batteries with overfill
protection no cell closing plug of former batteries
without overfill protection is used. This type of cell
closing plug has a vent bore at the top in cover.
Checking fluid level and adding distilled water
On batteries with overfill protection the fluid level is

determined by means of the marks on outside of
battery.
Refilling with distilled water
------
-------
------
------
------
-----
-----
----
---
---
--
-
q W
_---------------.
----------------
---------e-e----.
---------------_
_---------------.
----------------
1542-8181
54.5-00514
EXIT
The distilled water flows through circularly located

slots (4) into cell. The air displaced from cell flows
through 4 vent bores (3) into the open air.
3 Vent bores
4 Filling in slots
5 Diaphragm
When the fluid level is at max. mark it will L d 1542-8185
simultaneously close the vent ducts. As a result, the

air can no longer escape and an air cushion (2) is
established in cell. This air cushion prevents that
additional fluid can flow into cell from filler chamber.
The battery is filled up to max. capacity.
--- ------
_---- ___----- _-----
_--.
-----
._-----
----- ---_ ---------
---- ------
------
_--- __----
------- ------
_--------
__-- __ --
_----- __---------
- ---- ---
1 Vent duct __---- ___ ----I
---
2 Air cushion 1542-8180
Checking acid density
To check acid density, insert syphon through triple-

slotted diaphragm and remove required quantity of
fluid. Upon removal of syphon, the diaphragm will
again be watertight.
a = max. 9 mm
54.5-005/5
EXIT
Initial filling of battery with acid
During initial filling with acid insert the filling device

or a conventional funnel through diaphragm and fill
battery up to min mark.
1542-8182
a = max. 9 mm
_-------
-------
_____-I-
___----
_-_---- --------
- ---_----_
-------
1542-8184
a
Continue filling in acid up to max. mark through
slots with diaphragm closed.
Note: If a battery with overfill protection is scrapped,

remove rubber diaphragm for emptying.
III
---------------__
----------------
----------------_
----------------
----------------_
----------------
----------------_
1542-8183
54.5-00516
EXIT
54-100 Designation and layout of ground connecting points
Designation: Wl
Layout: Main ground, behind instrument cluster.
1 Ground for central electrics

2 Ground of harnesses
Designation: W 2
Layout: Ground, front right at lamp unit.
Designation: W 3
Layout: Ground, wheelhouse front left at

ignition coil.
54.5-100/l F 2
EXIT
Designation: W 5
Layout: Ground above engine (instrument

screwed into engine).
Designation: W 6
Layout: Ground, trunk on wheelhouse, left.
Designation: W 7
Layout: Ground, trunk at the right near tail

lamp unit.
Designation: W 9
Layout: Ground, front left at lamp unit.
54.5- 100/2 F 2
EXIT
Lefthand steering vehicle
Designation: W 10
Layout: Ground, battery
Righthand steering vehicle
Designation: W 10
Layout: Ground, battery
54.5-100/3 F 2
EXIT
54-140 Central electrics
A. Layout
The central electric system comprises the following

components:
- Fuses
- Double contact with relay air conditioning
- Overvoltage protection
- Combination relay (turnsignal, heatable rear
window, wiper)
The central electric system permits subdivision of main

harnesses used up to now into individual hernesses,
e.g.:
- Harness for rotary light switch
- Harness for headlamp, left
- Harness for headlamp, right etc.
The individual harnesses are connected to central

electric system by means of couplings.
The cast in switchplate connects the individual

harnesses with each other.
54.5-140/l
EXIT
Feeding of terminal 30 proceeds on face of central

electric system. In addition, there are other possible
connections on terminal 30, 15 and 15 R.
B. Association of harness couplings to coupling fields
Interior H Vacant P Relay overvoltage protection

Turnsignal (flasher) switch Electric window opener Headlamp, right
Tail lamp units K Door contact s Headlamp, left
Instrument cluster Lug, terminal 15/30 T Wiper motor
Ignition starter switch Motor
M ASS @ vacant)
Coupling with diode :: Air conditioning (engine side)
Slide roof
(@coupling with bridge) : Interior/air conditioning
Rotary light switch
54.5-l 4012
EXIT
C. Layout of screw connections
Lines to Cross section Color Engine version

mm2
Terminals 30, non-fused

Cable connector engine 6 red injection engine
carburetor engine
Fuel pump relay 2.5 red injection engine
Relay cutoff valve 0.75 red carburetor engine
Relay intake manifold heater 2.5 ted carburetor engine
ABS (except @ ) (special equipment):

Relay return pump 4 red
Relay magnetic valves 2.5 red
Auxiliary heater (special equipment):
Fuse element 2.5 red
Terminal 15, non-fused

ABS (except @ ) (special equipment):
Indicator lamp 0.75 black/red
Terminal 15R, non-fused

Airbag (special equipment):
Indicator lamp 0.75 black
Triggering unit
D. Layout of fuses and relays
.-.
3 16
.-
~_
__!E
6 .16-
R 1 Combination relay
(turnsignal, heatable rear window, wiper)
R2 Relay window opener
R3 Relay air conditioning
R4 Relay overvoltage protection
54.5-l 4013
EXIT
E. Layout of relays on relay holder
Note: The relay for heating intake manifold is marked

in blue on face.
Standard version
A Fuse element for auxiliary heater

B Fuse element for seat adjustment
C Relay for heating intake manifold
D Relay for headlamp cleaning system
l Relay for fuel pump (injection engines only)
659
A Vacant
B Fuse element for seat adjustment
C Relay for auxiliary fan 2nd stage
D Relay for comfort control, seat adjustment
l Vacant
F. Combination relay
The turnsignal flasher, the time relay of heatable

rear window, as well as the interval rewiper elec-
tronics of windshield wiper are combined in one
combination relay.
Note: The switched on heatable rear window is auto-

matically switched off by combination relay below a
battery voltage of approx. 11 volts.
Switching off is indicated by flashing of indicator

lamp in switch of heatable rear window.
When the voltage increases to above approx. 11 volts,

the heatable rear window is again automatically
switched on,
54.5-14014
EXIT
54-150 Central electrics, remove and install
Removal
1 Disconnect negative terminal of battery.
2 Remove cover under instrument panel (68-150).
3 Pull couplings (arrow) in interior from central

electrics.
4 Unscrew grounding strap (behind instrument

cluster) (1).
5 Remove relay holder (arrow).
54.5-150/l
EXIT
6 Open cover of central electrics on lock (1).
7 Unclip clamp (2).
8 Compress clamp (2) (arrows), disengage at hinges

at left (3) and right (4) and remove cover.
9 Unscrew fasteni ng (arrows, 2 Phillips head screws

at front and I 2 nuts at the rear).
10 Pull cer itral elextr ic system forward and lift,

unscrew lint3s from IU! 3 (arrow), pull off 1couplings
and remove central eltxtric system in for*ward
direction.
54.5-15012
EXIT
Installation
11 Move central electric system into installation

position, plug on couplings and connect lines at lug
(arrow) (for layout refer to 54-140).
12 Screw down central electric system, make sure

that ground connecting strap is located in interior.
1 3 Mount cov.er on central electric system, engage

clamp (arrows) in hinges at left (3) and at the right
(4) and clip to cover.
14 Mount relay holder.
15 Connect grounding strap.
16 Plug couplings on central electric system in interior

range.
1 7 Connect negative terminals of battery and check

electric system for function.
18 Install cover under instrument panel.
54.5-15013
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... EXIT
54-152 Electric connections of special equipment
The special equipment is connected to a 5pole cable

connector on lefthand side in legroom under lateral
panelling.
Layout of cable connector
a b C
Central electrics terminal 15 Central electrics terminal 30 Stop lamp switch terminal 54
designation black designation red designation yellow
Cruise control/tempomat Headlamp flasher, Portugal Cruise control/tempomat

Revolution counter Central locking system Anti-locking system
Adjustable outside rear-view control unit (ABS)
mirror Electronics, radio Burglar alarm system
Outside thermometer Rear compartment lamp
Exhaust gas/speed warning Automatic antenna
Seat heater front left Burglar alarm system
Seat heater front right Exit lamp
Burglar alarm system
Switchover valve rpm increase
(automatic transmission)
54.5-l 52/l
EXIT
54-250 Removal and installation of instrument cluster
Note
The instrument cluster is held in place by means of

five spring clips located on instrument panel.
1 Remove cover under instrument panel, left.
2 Remove hose (arrow) toward lefthand lateral nozzle

from below.
3 Unscrew tachometer shaft on instrument cluster

from below.
4 Push out instrument cluster from the rear.
5 Disconnect electrical connections and line for oil

pressure gauge, remove instrument cluster.
54.5-250/l
EXIT
Installation
6 For installation proceed vice versa.
7 When installing instrument cluster, push uniformly

into instrument panel.
Layout of 15pole coupling of instrument cluster
Model 201,022/024/l 22 1 st version
Model 201.034 1 st version
Model 201.023/024/034/122 2nd version
Note: 2nd version and model 201.034 1st version

with engine oil, coolant and washing water level
indicator.
Model 201.022/024/l 22 1 st version
No. Designation Line Line colors

cross section
1 Ground 0.5 brown

2 Sensor fuel reserve indicator 0.5 blue/green
3 Indicator lamp high beam 0.5 white/blue
4 Vacant - -
5 I nd icator lamp brake lining wear indicator 0.5 brown/red
6 Terminal 15, fused 0.5 black/blue
7 Terminal 15, non-fused 0.5 blue/red
8 Indicator lamp ignition terminal 61 0.5 blue
9 I nd icator lamp brake fluid readout 0.5 brown/red/white
10 Indicator lamp preglow system (diesel vehicles only) 0.5 black
11 Turn signal (flasher) control, right 0.5 black/green
12 Turn signal (flasher) control, left 0.5 black/white
13 Instrument lights terminal K 0.5 grey/green/purple
14 Temperature sensor, coolant 0.5 green
15 Sensor fuel gauge 0.5 blue/black
54.5-25012 F 2
EXIT
Model 201.034 1st version

cross section
Ground 0.5 brown

Temperature sensor coolant 0.5 green
Sensor fuel indicator 0.5 blue/black
Sensor fuel reserve indicator 0.5 blue/green
Switch engine oil level indicator 0.5 brown/blue yellow
Fuse 9, terminal 15, 0.5 black/blue
oil temperature indicator/voltmeter/stop watch
7 High beam checkup 0.5 white/blue
8 Terminal 15 unfused ignition starter switch 0.5 blue/red
9 Charge indicator terminal 61 0.5 blue
10 Contact sensor brake lining wear indicator 0.5 brown/red
11 Switch brake fluid checkup 0.5 brown/red white
12 Switch coolant level indicator 0.5 brown/green
13 Turn signal checkup right 0.5 black/green
14 Turn signal checkup left 0.5 black/white
15 Rotary light switch terminal K 0.5 grey/green purple
Layout of 4-pole coupling of instrument cluster 1st version

cross sect ion
1 Tank washer water system 0.5 brown/blue white

2 Line connector terminal 58 d 0.5 grey/blue
3 Switch parking brake 0.75 brown/red white
4 Warning buzzer contact 0.75 brown/green
54.5-25013 F 2
EXIT
Model 201.022/024/034/122 2nd version

cross section
Ground 0.5 brown

Temperature sensor coolant 0.5 green
Immersion tube sensor fuel indicator 0.5 blue/black
Immersion tube sensor fuel reserve indicator 0.5 blue/green
Switch engine oil level indicator 0.5 brown/blue yellow
Fuse 9, terminal 15, 0.5 black/blue
oil temperature indicator/voltmeter/stop watch 0.5 black/blue
7 High beam checkup 0.5 white/blue
8 Terminal 15 unfused ignition starter switch 0.5 blue/red
9 Charge indicator terminal 61 0.5 blue
10 Contact sensor brake lining wear indicator 0.5 brown/red
11 Switch brake fluid checkup 0.5 brown/red white
Switch parking brake 0.5 brown/red white
12 Switch coolant level indicator 0.5 brown/green
13 Rotary light switch terminal K 0.5 greylgreen
14 Turn signal checkup left 0.5 black/white
15 Turn signal checkup right 0.5 black/green
Layout of 4-pole coupling of instrument cluster 2nd version

cross section
1 Tank washer water system 0.5 brown/blue white

2 Line connector terminal 58 d 0.5 grey/blue
3 Warning buzzer contact 0.75 brown/green
4 Oil pressure sensor 0.75 brown/white
54.5-250/4 F 2
EXIT
54-25 1 Removal and installation of indicating instruments
Removal
1 Remove instrument cluster (54-250).
2 Remove speedometer (54-253).
3 Unscrew screws (6) and remove indicating

instruments (5).
Note: The lamp carrier can be separately renewed

(54-262).
2 Lamp carrier
5 Indicating instruments
Instrument lamps
: Optical turnsignal (flasher) control
C Acoustic turnsignal (flasher) control
Installation
54.5-251/l F 2
EXIT
54-253 Removal and installation of speedometer
1 st version
Removal
2 Remove regulating resistance (3).
3 Unscrew screws (1).
4 Unclip lamp carrier (2) (arrows).
5 Raise lamp carriers with acoustic turnsignal (flasher)

control (2) laterally and remove speedometer (4).
Installation
54.5-253/l F 2
EXIT
2nd version
Removal
1 Instrument cluster removed (54-250).
2 Remove rheostat (1).
3 Remove lamp carrier. For this purpose, unscrew

screws (2) and carefully pull off complete part.
4 Unclip check lamp for washer water level and

line (arrows).
54.5-25312 F 2
EXIT
5 Unscrew screws (4).
Remove speedometer.
Installation
54.b25313 F 2
EXIT
54-255 Checking indicator for economic driving (ECONOMY)
Special tools
Tester for vacuum O-1000 mbar 116589252100

g
$
Operation
The indicator is connected to the intake manifold by

way of a vacuum line and shows the momentary fuel
consumption in dependence of intake manifold
vacuum.
At a high intake manifold vacuum the needle is in

black field of readout (fuel consumption low), under
influence of falling intake manifold vacuum the
needle moves into red field. The momentary fuel
consumption increases.
With engine stopped, the needle is in red field against

red stop pin.
V a c u u m < 0.08 bar.
Upon starting of engine the needle travels to the left

and remains stopped in range of black indicating
field depending on vacuum.
Needle against lefthand stop > 0.585 bar.
Needle at starting point of red field approx. 0.4 bar.

1544-10869
54.5-25511 F 2
EXIT
Note
If the needle stops at righthand stop in red field,

there is a leak in vacuum line to indicator (connect-
ing point, line) or the indicator is defective.
Renew vacuum line and/or indicator.
If the readout is very slow, the cause may be oil in

vacuum line and/or in indicator. A defective dia-
phragm of vacuum control unit on automatic trans-
mission may cause oil to flow into vacuum system,
which will then lead to failure of indicator.
Checking
1 Pull vacuum line coming from intake manifold at

distributor (arrow) and check vacuum at engine
idle speed.
Nominal value: approx. 0.4-0.6 bar.
If nominal value is not attained, the vacuum line is

dirty or leaking. Clean or renew vacuum line.
If the nominal value is attained, connect vacuum

lines with each other, connect vacuum tester in-
between. Run engine at idle.
Needle of indicator should be positioned as follows:
1544-10669
Vacuum > 0.585 bar at lefthand stop.
Vacuum approx. 0.4 bar at start of red field.
If so, there is a leak in vacuum system of beam range

regulator and/or climate control.
Eliminate leaks.
If on vehicles with automatic transmission a vacuum

control unit on transmission is found to be defective,
oil may have entered the indicating instrument and
its line. Clean line and renew indicator.
54.5-25512 F 2
...... ......................... EXIT
54-256 Operation of transmitter for fuel gauge
Electrical function
Under influence of decreasing fuel level, the sliding

contact (1) on float (2) of immersion tube transmitter
will increase the resistance value, The current will
decrease and the indicator needle in instrument will
then fall back.
If the fuel level drops still further, the reserve warning

contact (5) in immersion tube transmitter, which
connects the reserve warning lamp ground, is closed.
,-
2
Transmitter (diagram) 5
1 Sliding contact
2 Float
3 Contact plate
4 Guide and contact rod
5 Reserve warning contact
54.5-25611 F 2
EXIT
p2e4
Fl
I I I - 0,7Sbl--- --b
1544-1133311
Electric wiring diagram fuel gauge
Al Instrument cluster C 16-pole coupling (tail lamp unit harness)

e4 Fuel reserve warning D 16-pole coupling (instrument cluster)
p2 Fuel gauge E 8-pole coupling (ignition starter switch)
B4 Transmitter fuel gauge U 8-pole coupling (engine harness)
Fl Electrical center a To ignition starter switch S2/1 terminal 15
Main ground (behind instrument cluster) b To line connector X35 terminal 30/61
w: Ground, trunk on wheelhouse left (battery) terminal 61
54.5-25612 F 2
EXIT
54-257 Testing fuel gauge
Test values transmitter, fuel gauge
Resistance with float at top 1.9 * 0.7 s2
Resistance with float at bottom 78.3 2 2.3 L!
Note
The reserve warning lamp lights up with ignition

switched on (checking function). As soon as the
engine starts running, the lamp goes out provided the
fuel tank holds more than the fuel reserve.
During checking function, the reserve warning lamp

will light up weaker, for reserve stronger.
Testing transmitter, fuel gauge (removed)
Connect ohmmeter to terminal G and terminal 31 (I)

and measure resistance.
a) In installation position (readout reserve, float

below).
b) 1 80 turn (readout full, float at top).
Testing reserve warning contact
Connect ohmmeter to terminal W and terminal 31 (1)

and measure resistance.
a) Nominal value approx. 0 a in installation position.
b) Nominal value 00 L? turned by 180.
54.5-25711 F 2
EXIT
Testing harness
1 Pull coupling from transmitter of fuel gauge and

measure resistance on jack 3 and vehicle ground.
Nominal value approx. 0 52
(At test value 00 R the grounding line is interrupted),
2 Measure resistance on terminal G and terminal

31 (I) on installed transmitter of fuel indicator. The
value depends on fuel content.
Put coupling back on transmitter for fuel gauge.
3 Pull coupling from instrument cluster and measure

resistance between jack 1 and jack 15.
Nominal value: the value measured under 2. If the

value is attained, the harness is in order (slight
deviation caused by length of line is possible).
4 If the measured value is higher or at 00 CZ, the

harness couplings (on instrument cluster, on main
harness/tail lamp unit harness or on fuel gauge
transmitter) are having poor contact, a dry solder
joint or a line is interrupted.
5 If no fault is found during tests, exchange

indicating instrument.
54.5-25712 F 2
EXIT
54-258 Removal and installation of time clock/revolution counter
Removal
3 Unscrew screws (8) and remove time clock/

revolution counter (7).
Installation
54.5-25811
...........................................................................................
EXIT
54-26 1 Testing electric outside temperature indicator
Test values
OC Resistance (ohms)
0 9 7 9 8 + 98
20 3747?71
40 1598t40
Resistance values of temperature sensor in dependence

of temperature.
Note
The temperature sensor is installed at front bumper

b e h i n d licence plate.
The temperature indicator in instrument cluster is

connected to voltage at key position 2. The tem-
perature sensor activates the temperature readout
according to outside temperature.
54.5-261/l
EXIT
Testing
1 Remove cover under instrument panel at the left.
2 Separate 3-pole plug connection of temperature in-

dicator behind instrument cluster.
3 Move ignition starter or glow starter switch into

position 2
4 Test for battery voltage with voltmeter at 3-pole

coupling between lines 0.75 brown and 0.75 black/red.
If there is no voltage, repair interruption in line

0.75 black/red to cable connector interior or line
0.75 brown to main ground behind instrument cluster.
Plug connections
1 2-pole
2 3-pole
With voltage or ground connection indicated, separate

2-pole plug connection of temperature indicator behind
instrument cluster and measure resistance between the
two line plugs brown and green toward temperature
sensor (test values).
In the event of deviationes from nominal value, renew

temperature sensor together with electric line.
5 If electric lines, voltage supply and temperature

sensor are in order, remove instrument cluster and
renew outside temperature indicator.
54.5-261 I2
EXIT
Alp4
0,5sw/rt
0,5gr/bl
0,5br -
Electric wiring diagram outside temperature indicator
Alp4 Outside temperature indicator

Bl O/5 Outside temperature sensor
Wl Main ground (behind instrument cluster)
x5/1 Line connector interior A/B terminal 15
X6 Line connector terminal 58 d
X67 Plug connections outside temperature indicator
54.5-26113 F 2
EXIT
54-262 Renewing lamp carrier with acoustic turn signal checkup
Note
On lamp carriers of 1st and 2nd version the lines are

soldered-on. On 3rd version, the lamp carrier is
connected to the indicating instrument with a plug
connection,
3 Remove indicating instruments (54-251).
1st and 2nd version
4 Unscrew bulbs from removed lamp carrier and

unsolder electric lines.
Lamp carrier
Indicating instruments
instrument lights
Optical turn signal checkup
Acoustic turn signal checkup
5 Solder new lamp carrier to the 4 lines of the

indicating instrument. Make sure that only lines
with the same numbers (depending on version) are
connected to each other.
54.5-26211 F 2
EXIT
1 st version
Indicating instrument with lamp carrier
(conductor board)
2nd version
Indicating instrument with lamp carrier
(conductor board)
6 Insert bulbs, assemble instrument cluster and

mount back again on instrument panel.
7 Check electrical system for function.
54.5-26212 F 2
EXIT
54-264 Checking washer water level indicator
X27
a
II I
f b d
1543-1246012
S42
Electric wiring diagram engine oil level indicator, coolant level indicator, washer water level indicator
gasoline and diesel-engines-
Al Instrument cluster B5 Transmitter oil pressure indicator

el Turn signal checkup left s41 Switch coolant level checkup
e2 Turn signal checkup right S42 Switch washer water level checkup
e3 High beam checkup s43 Switch oil level checkup
e4 Fuel reserve warning w2 Ground, front right (near lamp unit)
e5 Charge indicator X27 Plug connection starter harness
e6 Checkup brake lining wear indicator Main ground behind instrument cluster
e7 Checkup brake fluid and parking brake : Electrical center coupling D jack
e8 Instrument lights terminal 15 unfused
ell Checkup coolant level C Electrical center coupling D jack 2
e12 Checkup oil level terminal 15 fuse 9
e13 Checkup washer water level d Electrical center coupling D jack 8
e16 Preglow checkup alternator terminal 61
hl Warning buzzer Preglow time relay terminal La (diesel
. engine only)
h2 Turn signal checkup, acoustic Ground connection points wrthout deslgnatron -
Pl Temperature indicator, coolant component directly on engine or body
P2 Fuel gauge
P3 Oil pressure indicator
~6 Electronic clock
54.5-26411 F 2
EXIT
Test values
Resistance on washer water level indicator

at water level ,,max
Resistance on washer water level indicator

approx. 5 52
at water level ,,min
Battery voltage approx. 12 V
Conventional tool
Multimeter e.g. Sun, DMM-5
Note
The indicator lamp lights up with the ignition

switched on (checking function) and goes out as
soon as the engine is running.
When checking function the indicator lamp lights

up weakly, and brightly in the event of an inter-
ruption.
Engine oil level indication

2 Coolant level indication
3 Washer water level indication
The washer water tank is fastened by means of a

knurled nut.
54.S26412 F 2
EXIT
In the event of complaints, such as:
A. Indicator lamp constantly lighting up with engine running and correct washer water level.
B. Indicator lamp not lighting up in key position ,,2.
C. Indicator lamp not lighting up with engine running and washer water level below ,,min.
Testing
A. Indicator lamp constantly lighting up with engine

running and correct washer water level
Testina washer water level indicator
W ith coupling pulled off, connect both plugs

with multimeter and test resistance.
Readout: 00 G!
Renew washer water level indicator.
Testing line
Remove instrument cluster. With multimeter

connected to jack 1 of 4-pole coupling, test
against ground (coupling plugged on washer
water level indicator).
Readout: 00 L?
ves
I Eliminate short to ground.
I Renew indicating instrument.

I
End of test.
54.6-26413 F 2
EXIT
6. Indicator lamp not lighting up in key position ,,2
I Renew bulb.
Remove instrument cluster. Measure voltage,

with multimeter connected to jacks 6 and 9
of 15-pole coup1 ing.
Readout: approx. 12 V
0
V
Eliminate interruption according to

electrical wiring diagram.
I
I Renew indicating instrument.
End of test.
54.5-26414 F 2
EXIT
C. Indicator lamp not lighting up with engine

running and washer water level below ,,min
(section ,,B in order)
Testing washer water level indicator
With coupling pulled off, connect both plugs

with multimeter and test resistance.
Readout: approx. 5 R
Renew washer water level indicator.
Testing line
Connect multimeter with 2-pole coupling

for washer water level indicator (brown
line) and battery positive.
Readout: approx. 12 V
yes
I no
I Test ground connection, correct.
Bridge coupling for washer water level

indicator. Indicator lamp should light up
in key position ,,2.
I no
Eliminate interruption according

to electrical wiring diagram.
End of test.
54.5-26415 F 2
EXIT
54-266 Operation of auxiliary instruments model 201.034
Voltmeter
The voltmeter is connected to terminal 15 of 15-pole

coupling of instrument cluster (jack 6). When the
ignition is switched on, the voltage connected there
is indicated.
Oil temperature indicator
The indicating instrument shows the oil temperature

in oil filter housing by way of a transmitter.
1 Voltmeter
2 Oil temperature indicator
3 Stop watch
Stop watch
In key position ,,2 the following functions can be

called by means of the 3 buttons.
1 Button for measuring time
2 Button for measuring average speed on 1 km

driving distance
3 Button for cancelling measured time

i
1. Measuring time
Pushing button 1 = start. The colon between digits

will flash.
Pushing button 2 = stop. The stopped time is shown

in display window.
Pushing button 3 = indication cancelled, or ignition

off = indication cancelled.
54.5-26611 F 2
.................................................................:..........................................
..................
0.. . . . . . . . . ...............................
EXIT
Time indication in display window:
From 0O:OO to 59:99 = seconds and /Im seconds.
After 1 minute from 01:OO to 59:59 = minutes and

seconds.
After 1 hour from 01:OO to 09:59 = hours and

minutes.
2256
After 10 hours the time will again be measured in

seconds and 1/1oo seconds.
2. Measuring average speed for driving distance of

1 km
Pushing button 2 = start. Colon in display window

will flash.
Push button 2 again after driving 1 km = stop. The

attained average speed is shown in display window.
Cancelling readout: push button 2 or switch off

ignition.
3. Measuring average speed for driving distance of

1 km while measuring time
The average speed can also be measured while

measuring time. This will not interrupt measuring
of time.
Pushing button 2 while measuring time = start,

colon in display window will flash.
Pushing button 2 once again after driving 1 km =

stop. Display window shows the attained average
speed.
Pushing button 2 = display field shows the time

running on.
Cancelling readout: push button 2 or switch off

ignition.
54.5-266/2 F 2
EXIT
Wiring diagram auxiliary instruments Model 201.034
Bl A5
X6 wi a
.-.-. I I
1 c++--- 0,5gr/bl' A 0,5gr/bl
-.-
1 st version
A3 Voltmeter
A4 Stop watch
A5 Oil temperature indicator
Bl Oil temperature transmitter
X5/2 Line connector interior/starter
a To 15-pole coupling instrument cluster jack 6, terminal 15
Grounding points without designation -
component directly on engine or body
Bl A5 A4 A3
1 ot 0,5gr/bl d ;0,5gr/bl 1
1543-1228313
-._
2nd version
A3 Voltmeter
A4 Stop watch
A5 Oil temperature indicator
Bl Oil temperature transmitter
WI Main ground (behind instrument cluster)
X5/2 Line connector interior/starter
a To 15-pole coupling instrument cluster jack 6, terminal 15
Grounding points without designation -
component directly on engine or body
54.5-26613 F 2
EXIT
54-267 Removal and installation of auxiliary instruments
Removal
1 Remove ashtray with holder.
2 Unscrew both fastening screws (1) and pull out

console in downward direction, so that the two
locking points (arrows) of center console are re-
leased.
3 Pull the 3 couplings from individual instruments.
Installation
For installation proceed vice versa. Make sure that

the longer electric line with 3-pole coupling is
plugged on voltmeter.
54.5-26711 F 2
EXIT
54-395 Sun visor with illuminated mirror
The mirror integrated in sun visor is provided with

lights, which are switched on by swivelling the cover
(1) in upward direction.
The lights are located at the left and right adjacent

to mirror (arrows).
The voltage supply (positive and negative) for the

lights comes from a pair of contacts (arrows) inte-
grated in mounting bracket.
54.5-39511 F 2
EXIT
Unclip mirror for exchanging bulbs.
The switch contact for switching on the lights is

located on hinge of cover (arrow).
54.539512 F 2
EXIT
54-410 Warning device for safety belt, ignition key, light @
The warning unit comprises 3 functions:
1. Warning when safety belt is not put on
2. Warning when ignition key is not pulled off
3. Warning when light is not switched off
Operation
If with the ignition switched on and the drivers

door closed (door contact switch left [7] opened)
the safety belt is not put on by the driver, the
warning buzzer will sound for 4-8 seconds. For
this purpose, the electronic system of warning
unit (2) is connected from terminal 10 via closed
belt switch (terminal 9 of warning unit), positive
to warning buzzer in warning unit.
When the safety belt is put on, the belt switch

will interrupt the circuit and the warning buzzer
is switched off.
The check lamp (1 r) connected in parallel with

belt switch is operational up to end of respective
time (4-8 seconds).
If with the drivers door open (door contact switch

left [7] closed) the ignition key is not pulled off,
the warning buzzer is positively activated by the
electronic system via closed warning buzzer con-
tact on ignition lock (5), terminal 5 on warning
unit. The warning buzzer is switched off by pulling
the ignition key off or after 4-8 seconds.
If the high beam, the low beam or the parking

light are not switched off, with the ignition
switched off, when the drivers door is opened,
this will also be indicated by the warning buzzer.
The warning buzzer is positively activated by

terminal K on rotary light switch via electronic
system in warning buzzer (terminal 4). When the
drivers door is opened, the electronic system is
negatively activated via the closed door contact
switch left (7) and the warning buzzer will sound
off.
54.5-410/l F 2
EXIT
54-500 O p e r a t i o n
The cruise control/Tempomat system is ready for use when the ignition is switched on. However, for actual
operation, the vehicle speed should be above approx. 40 km/h. When the vehicle is running at the desired speed,
touching of pushbutton switch for a short moment in direction of ,,accel - set or ,,decel - set serves to main-
tain this speed until the driver has set a new speed or switched off. To adapt the set speed e.g. to the traffic flow,
hold pushbutton switch in direction of ,,accel - set or ,,decel - set until the desired speed is attained. On
vehicles with new control unit (phased-in starting 9.86), recognized by coding plug, touching of pushbutton
switch in direction of ,,accel - set or ,,decel - set will increase or reduce the speed by 1 km/h. The vehicle is
accelerated at a controlled 0.7 m/s2. The new speed will be held after the pushbutton switch is released. The
cruise control/Tempomat is switched off when touching the pushbutton switch for a short moment in direction
of ,,Off, when stepping down on brake pedal or on clutch pedal, the throttle control will move into idle speed
position.
Switching off with pushbutton switch will activate the actuator motor, which moves the throttle control into
idle speed position. On the other hand, when switching off by stepping down on brake pedal or clutch pedal, the
power flow in actuator is immediately interrupted, the electromagnetic clutch will then be de-energized and a
return spring will pull one gearwheel of actuator gear unit out of mesh. The return springs will pull the throttle
control into idle speed position. After switching off, the system remains operational until the ignition is switched
off. If upon actuation of brake or clutch or after switching off, the pushbutton switch is touched for a short
moment in direction of ,,resume at a vehicle speed above approx. 40 km/h, the vehicle will be automatically
accelerated at 1 m/s2 to the speed ,,set last. The speed set last is cancelled when the ignition is switched off.
If the set speed is exceeded by accelerating, e.g. when passing another car, the vehicle will automatically
return to the previously set speed when the accelerator pedal is released.
If the engine capacity is inadequate when driving uphill, the set speed will drop and will be automatically
m-established as soon as the gradient has been overcome if the speed has not dropped below 40 km/h or the brakes
have not been actuated in the meantime.
If engine braking effect is inadequate when driving downhill, the set speed is exceeded and the vehicle must be
braked if necessary. If brakes were not actuated, the set speed will be automatically re-established as soon as the
gradient is overcome.
Attention!
While driving with cruise controI/Tempomat, the selector lever position N of the automatic transmission
should not be engaged, since otherwise the engine will rev up.
Safety shifts
The speed set last in control unit will be cancelled when the ignition is switched off.
When the ignition is switched on, the value ,,0 km/h is put into speed memory (Sp = Resume).
This will make sure that no unknown speed will be held in memory (resumed) when another trip is started, e.g.
after changing the driver.
54.8-500/l F 2
EXIT
The speed is constantly monitored by the control unit. Each change of speed is picked up and evaluated. On
control unit without coding plug by means of a shift step (differentiating link), on control unit with coding
plug by means of a computer.
If a speed change is made with pushbutton switch, the shift step (differentiating link) together with an operation
amplifier or the computer in control unit will make sure that the specified values are maintained at switch posi-
tions ,,accel - set of 0.7 m/s* or at ,,resume of 1 m/s*.
When braking or clutching, the electromagnetic clutch in actuator will be de-energized, the power flow will be
immediately interrupted, since a return spring will pull one gearwheel of actuator gear unit out of mesh. The
return springs will pull the regulating linkage into idle speed position.
If, for example, with a defective stop lamp switch, the vehicle is decelerated > 1.5 m/s*, these data will be
picked up on control unit without coding plug by the shift step (differentiating link) in control unit. The sub-
sequently connected threshold value switch will activate the actuator motor, which will move the regulating
linkage into idle speed position. On control unit with coding plug the delay is picked up by the computer and
the power flow in actuator is interrupted similar to procedure while braking or clutching, since the electro-
magnetic clutch in actuator will be de-energized.
The time interval up to cutout depends on extent of delay.
If the nominal speed is exceeded by more than approx. 6 km/h for any reason whatsoever, the speed monitoring
unit will react. The electromagnetic clutch in actuator will be de-energized, the power flow in actuator is inter-
rupted and the regulating linkage will move into idle speed position. If the speed is subsequently less than approx.
6 km/h, e.g. the speed is now only 5 km/h higher than the nominal speed, the electromagnetic clutch is again
activated and the power flow in actuator is again established.
The operation of the electromagnetic clutch in actuator is monitored by the control unit (amplifier) each
time the brakes are actuated. If the power flow in actuator is not interrupted in the event of a defective
clutch, the control unit will activate the actuator motor which will then move the regulating linkage into idle speed
position. This process is recorded by the control unit (amplifier) and the system will be made inoperative until
the ignition is switched off. When the ignition is switched on again, the system will operate normally up to the
next braking operation, when it will again be made inoperative under influence of defective electromagnetic
clutch.
54.8-50012 F2
EXIT
The cruise control/Tempomat system comprises the

following components which are connected to each
other by means of an electric harness.
Pushbutton switch
Position 1 or
2 touch = speed is set.
Position 1 hold = set speed is increased.
Position 2 hold = set speed is reduced.
Position 3 touch = cruise control is switched off.
Position 4 touch = the speed set prior to switching off
is automatically re-established at a
speed of above approx. 40 km/h
(approx. 25 mph).
Control unit (amplifier)
The control unit (amplifier) (N4) compares the

actual and the desired speed. In the event of a
deviation from the desired speed, the control unit
(amplifier) (N4) transmits the pertinent control
signals to the actuator (M16) until the actual and
the desired speed are again in agreement.
Transmitter
The control unit (amplifier) receives the actual speed

signals from transmitter (L2) on speedometer.
54.8-50013 F 2
EXIT
Actuator
The actuator (M 16) receives its control signals from

control unit (amplifier) and actuates the regulating
linkage by way of a connecting rod. The actuator
comprises an electric motor with gear unit, a one-
way clutch, a potentiometer and an electromagnetic
clutch.
The electric motor drives the output shaft provided

with a one-way clutch by way of the gear unit.
The one-way clutch permits, e.g. with the speed set,

acceleration with accelerator pedal for passing other
vehicles without a need for actuating the cruise
controI/Tempomat.
The potentiometer reports the position of the output

shaft to the control unit/amplifier.
The electromagnetic clutch establishes the power

flow between the electric motor and driven axle by
engaging a gearwheel. It is engaged at the following
switch positions: accel - set, decel - set and resume.
The electromagnetic clutch is switched off by actu-
ation of brake or clutch, but also when the system is
switched off by means of pushbutton switch and
when the regulating linkage has attained the idle
speed position. When the electromagnetic clutch is
switched off, the power flow is immediately inter-
rupted by a return spring, which pulls a gearwheel
out of mesh.
Switch on manual transmission actuated by

clutch pedal
When stepping down on clutch pedal, the ground

connection from stop lamps to control unit (ampli-
fier) is interrupted by the switch (S40/1). The cruise
control/Tempomat will then be switched off
immediately similar to procedure while braking.
Relay on model 201.024 (standard version)
During operation of cruise control/Tempomat the

relay will make the decel shutoff inoperational. The
relay is painted yellow on surface for identification.
54.8-50014 F 2
EXIT
54-504 Testing with adapter
Special tool
126 589 0521 00
Prerequisite for testing
Prior to testing with adapter, check battery voltage (> 11 V), stop lamps and speed indicator for function. If
required, recondition according to condition and test cruise control/Tempomat for function prior to test by
means of adapter.
Test cruise control/Tempomat with adapter only. If other testing and measuring instruments are used, the cruise
control/Tempomat may be destroyed. During this test, the cruise control/Tempomat is tested with the exception
of the control unit.
Faults can be found by means of adapter only if the cruise control/Tempomat is continuously inoperational.
Complaints such as periodical failure or poor control characteristics (e.g. shaking) cannot be tested by means of
the adapter. In such cases, proceed according to programmed repairs.
If testing with the adapter indicates a faulty component, check plug connections for good contacting prior to
replacement. Plug sockets, for example, should not be widened. Widened plug sockets should be reshaped. Then
check rejected component once again,
Preparing for test
1 Expose control unit (amplifier) (refer to 54-565).
2 Pull 14-pole coupler from control unit (amplifier).
3 Connect test adapter to 14-pole coupler.
4 Switch on ignition. LED-readout of symbols for

battery, km/h and ground will light up, provided no
fault is indicated.
I -------I
5 Push button LED-TEST of test adapter and I
check whether all LED-readouts are lighting up. If no / 1x1 126669052100 a~ TEMPOMAT I
LED-readout is lighting up, test connection of voltage
supply and layout of 14-pole coupler (refer to wiring LED-TEST
diagrams 54-580).
I
1543-9600
54.8-504/l F 2
EXIT
Survey test program
Test step Actuation Nominal readout Possible cause for deviation from
nominal readout
LED readout Lines wrongly connected.

lights up Lines are interrupted.
LED readout Grounding bridge in 14-pole

lights up on connector interrupted.
models with 77!77
grounding bridge.
LED readout Perform test step 6.

may light up. 0
Actuate cruise Pertinent Lines interrupted.

control switch LED readout Switch defective.
(positions 1-4) lights up.
Push push-
button switch. 0!I!! Regulating linkage
moves uniformly
Regulating linkage and accelerator pedal
not moving:
to full throttle Connecting rod not connected to actuator
position and stops. or regulating linkage.
Lines interrupted or wrongly connected.
Switch on clutch pedal defective. Actuator
defective.
Regulating linkage and accelerator pedal
constantly moving to and fro.
Poor contacting of plug connection
harness/actuator harness.
Actuator defective.
4 Push push-
button switch. 0!! When operating
brake pedal, regu-
Regulating linkage hard to move.
Actuator defective.
Regulating linkage lating linkage will
in full throttle move immediately
position. Step into idle speed
down on brake position.
pedal. Then release
pushbutton switch.
5
with
Push push-
button switch. 0I!! Regulating linkage
will move imme-
Lines shorted.
Switch on clutch pedal defective.
manual Regulating linkage diately into idle
trans- in full throttle speed position,
mission position. Step when operating
only down on clutch clutch pedal.
pedal. Then release
pushbutton switch.
6 Move vehicle, LED readout Lines interrupted or wrongly connected.

at least for flashing Sensor (transmitter) defective.
0
2 wheel turns
If no fault was found on previoos tests:

1. Test blue line from connector actuator jack 5 to connector control unit jack 10 for short to ground by means of ohmmeter.
2. On control units with coding plug, test coding plug R 29 (54-506).
3. Mount new c?ontrol unit for tryout.
54.8-50412 F 2
EXIT
Test
I
.x 1 2 6 669 05 2 1 0 0 BE TEMPOMAT ~
Test voltage supply.

@I LED-TEST
I LED-readout lights up
I yes I no
1543-9604
Test lines for correct connection and

for passage.
W7W6
s40
M 16
q75w
0,75 r 1
0,75 bf
~,%Ngc
b
w :
-1.
-Q- I. N4 I
.-.-.-.-. -I -.-..
1543-11980r3
Example: 201.122 up to approx. 8.85
N4 Control unit cruise control/Tempomat

S40 Pushbutton switch cruise control/Tempomat
a To central electrical system F 1, connecting field L assignment 1
54.8-50413 F 2
EXIT
For vehicles with grounding bridge (refer to

12658905210() B E TEWOMAT
wiring diagram 54.8-5801, test in 14-pole 8
connector,
LED readout lights up

yes no
I
1543-9606
Recondition grounding bridge in

14-pole connector.
W7 W6
Ml6
475 bl
0,75gn
qS bl
qsgn
1
q75ws qsm
R
a

54.8-50414 F 2
EXIT
Test harness and pushbutton switch.
Switch position LED-readout
Accel
Decel
Off
Resume
-__ _~
Respective LED-readout lights up
yes no
I
Test lines for correct connection and passage.

Renew switch.
W7W6
T
e-
154%1196lI3

S40 Pushbutton switch cruise control/Tempomat
B Accel
V Decel
A Off
SP Resume
54.8-50415 F 2
EXIT
Test actuator.
4, 126569052100 BE TEMPOMAT
Push pushbutton switch M. b
Throttle control and accelerator pedal are

Eni 8 0 LED-TEST
moving uniformly to full throttle position

and stop.
Y

not moving:
Test throttle control.
Test lines for correct connection or

passage (54-580).
On vehicles with manual transmission,

test switch on clutch pedal for passage.
Renew actuator.

constantly moving to and fro:
Test contacting of plug connections

harness/actuator harness and harness/
control unit.
Renew actuator.

not pulled to full throttle position:
1. Test contacting of lines for actuator

and ground for control unit.
2. Renew actuator.
54.8-504/6 F 2
EXIT
W7W6
Ml6
I .
I
.
! N4
Example: 201,122 up to approx. 8.85
Ml6 Actuator cruise control/Temoomat

N4 Control unit cruise control/iempomat
s9 Stop lamp switch
A. 126669052100 BE TEMPQMAT ~
Test cruise control-cutout while braking.
Pushbutton switch _M is pushed. I El a 9 0 LED-TEST
Throttle control and accelerator pedal are in full
throttle position!
Depress brake pedal.

J
immediately moving into idle speed position. 1543-9612
Then release pushbotton switch.
Test throttle control for easy operation.

Renew actuator.
54.8-50417 F 2
EXIT
Test cruise control/Tempomat-cutout while 1% 126 589 05 2100 BE TEMPOMAT

declutching (with manual transmission only).
Pushbutton switch _M is pushed.
Throttle control and accelerator pedal are in full
throttle position!
Depress clutch pedal.
Throttle control and accelerator pedal are moving

1543-9612
immediately into idle speed position. Then release
pushbutton switch.
yes I no
Lines are shorted.

Switch on clutch pedal defective.
.-.-.
W7W6
r
s40
1
Ml6
N4
Ml 6 Actuator cruise control/Tempomat

Control unit cruise control/Tempomat
ss Stop lamp switch
S40/1 Switch clutch pedalxruise control/Tempomat
54.8-50418 F 2
EXIT
!st harness and transmitter (sensor) on g 126589052100 BE TEMPOMAT

eedometer, the speed readout must be in
der.
8 @ LED-TEST
ove vehicle, for at least 2 turns of
heel.
ED readout flashes or lights up.

?S no
I
On vehicles with Hall-effect speed sensor

(starting approx. 9.85), test voltage supply
(terminal 15) of Hall sensor on black line
of 2-pole Hall sensor connector according
to wiring diagram (54.8-580).
Test lines according to wiring diagram for

short circuit and interruption.
Renew sensor.
W7W6
E4 E3
Ml6
- Y
_Y-
- q?5sw
II,?5 bf
0,759n
I. N4
L2 Inductive transmitter speed

54.8-50419 F 2
EXIT
I Disconnect test adapter.

I
Test blue line from connector actuator jack 5

to connector control unit jack 10 with ohm-
meter for short to ground.
Short to ground
no w
I
Recondition or renew blue line.
W6
E4 T E3
ab
w/r, - x2o s9
1 swlrt-VI
0,75 SW ~--pi+--1 SW
-_ _i
I I I I I I I I
Ml6 Actuator cruise control/Tempomat

54.8-504/10 F 2
... .............. ... ............ EXIT
On control units with coding plug, test coding

plug (R29), 54-506.
Coding plug in order

yes no N4/2
I
Renew coding plug (R29), 54-577
End of test
54.8-504/l 1 F2
...................................................................... ........................................ EXIT
54-506 Testing coding plug
R29
a
b -C
Coding plug (R 29) .,..... . . . . . . . . . . . . . . Remove (54-577). Production date (a),

part number (b), pin socket designation (c).
On some coding plugs there is no pin socket designation
A-G. These coding plugs must be tested as shown in
illustration at the right.
Ohmmeter ............. . . . . . . * . . . . . . . Connect (refer to Table).
Resistance values ......... . . . . . . . . . , . . . . Test (refer to Table), renew coding plug (R 29) if values
deviate.
Test table - resistance values

I I I
Part number to pin socket designation
D-H D-C A-D
52 a
2.88- 3.00 kR 00
0055454232 3 . 1 8 - 3.30 ka 00
0065452532 1.98- 2 . 0 2 kS2 < 10
325.4 -338.6 a 00
3 . 9 2 - 4.08 ka =
*This value cannot be measured with multimeter SUN DMM-5.
Conventional tool
SUN DMM-5
Multimeter or
Thorn Emi Avometer 2003
54.8-506/l F 2
EXIT
54-541 Removal and installation of actuator
A. Engine 102
Battery ................................Disconnect
Air cleaner (except engines with Stromberg
carburetor) ..............................Remove
Engine compartment lining, below
(on injection engines only). ................... Remove
Plug (1) on holder of diagnosis socket or on
holder of hydraulic unit ABS .................. Pull from connector
Line of actuator (Ml61 ......................Expose
Connecting rod (2) on actuator (M16) ............ Disengage
Starter (on engine 102.983 only). ............... Remove
Fastening nuts (3). .........................Unscrew
Actuator (Ml61 with holder. .................. Remove; on engines with injection system (except
102.983) remove ignition distributor cap and distributor
finger, loosen distributor if required and turn clockwise
toward engine or remove, set ignition following instal-
lation. On engine 102.983, extend actuator (M16) first
at the two rear studs and remove with holder in down-
ward direction.
..................
Fastening screws (4) M6x28. Unscrew, 12 Nm
Lock washer (6). ..........................Unlock
Fastening nut (5)..........................Unscrew, 10 Nm
Installation. .............................In vice-versa sequence, while turning drive shaft of
actuator (M16) opposite to direction of arrow against
stop, lever (A Stromberg carburetor; B 2 E-E carburetor;
C injection engines, except 102.983; D engine 102.983)
mount and secure nut (5)
Function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . Perform on road
54.8-54111 F 2
EXIT
B. Engine 103
\
@0,
00 4
%J
1542-14761
Air cleaner ..............................Remove
Engine compartment lining, below .............. Remove
Plug (1) model 124 on holder of diagnosis socket
or model 201 on holder of hydraulic unit ABS ...... Pull from connector
Line of actuator (M16) ......................Expose
Fastening screws ( 11) M6x 12 and (8) M8x30 ....... Unscrew
Actuator (Ml61 with holder. .................. Remove in downward direction. On model 124 with
refrigerant compressor, loosen fastening screws for
engine mounts and lift engine.
Fastening screws (4) M6x28. .................. Unscrew, 12 Nm
Fastening nut (5) ..........................Unscrew, 10 Nm
Installation ..............................In vice-versa sequence, while rotating drive shaft of
stop. Mount lever (E) and secure nut (5)
Function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . Perform on road
54.8~54112 F 2
EXIT
C. Engines 601, 602.91 and 603.91
Plug (1) between coolant expansion tank and
washer reservoir. ..........................Pull from connector
Fastening screws for shielding plate on holder
(1st version only)..........................Unscrew
Fastening screws (7) M6x18. .................. Unscrew
Actuator (M16) with holder. .................. Remove
stop, mount lever (F) and secure nut (5).
Function test . . . . . . , . . . . . . . . . . . . . , . . . . . . . Perform on road
54.8~5w3 F 2
EXIT
D. Engine 602.961
1542-14757
Battery ............................... Disconnect

Plug (1) on holder for hydraulic unit ABS. ........ Pull from connector
Line of actuator (Ml 6) ......................Expose
............ Disengage
Connecting rod (2) on actuator (M16)
Actuator (Ml61 with holder. .................. Remove
Lock washer (61. ..........................Unlock
stop, mount lever (G) and secure nut (5).
Function test ............................Perform on road
54.8-54114 F 2
............................................ ................. ............................... ............ EXIT
E. Engine 603.96
Ml6
w 1542-14760
Air cleaner ..............................Remove
Plug (1) on holder of diagnosis socket ............ Pull from connector
Regulating linkage and control pressure
cable control ............................Disengage
Actuator (Ml6) with holder. .................. Remove
Installation ..............................In vice-versa sequence, while turning drive shaft of
stop, mount lever (H) and secure nut (5).
Function test . . . . . . . . . . . . . . . . . , . . . . . . . . . . Perform on road
54.8-54115 F 2
................................................................................................................... ...................................................... EXIT
54-545 Removal and installation of switch, cruise control/Tempomat
A. Model 124 and 2nd version model 201 starting approx. middle of April 84
Battery. ................................Disconnect
Cover at Jeft under instrument panel ............. Remove (68-150)
Steering wheel (1) .........................Remove
Plug for switch (S40) .......................Pull off
Fastening screws (2) ........................Unscrew
Combination switch (S4) with switch (S40). ........ Pull out for approx. 5 cm
Line holder (4) ...........................Remove from clips
Cruise control switch (S40) ................... Pull from combination switch (S4)
Cruise control switch(S40) ................... Remove, while pulling up steering column lining (3)
on model 201
Rubber grommet (5). .......................Remove from cruise control switch(S40)
Installation ..............................In vice-versa sequence
54.8-54511 F 2
EXIT
B. 1st version model 201 up to approx. middle of April 84
Cover at left under instrument panel ............. Remove (68- 150)
Plug for cruise control switch (S40) .............. Pull off
Steering wheel (1) .........................Remove
Steering column lining (3) .................... Remove
Clamps (6) on combination switch (S4) ........... Remove from clips
Fastening screws (2) ........................Unscrew
Cruise control switch (S40) ................... Remove
54.8-54512 F 2
EXIT
54-550 Removal and installation of transrmitter
1543- 14705
Instrument cluster .........................Remove (54-250)

Harness of transmitter. ...................... Pull off
Fastening screw of transmitter ................. Unscrew and remove transmitter
Installation. .............................In vice-versa sequence
Note
Model 124 and model 201 as of approx. 1985

Hall sensor road speed (B6)
Model 201 up to 1984 inductive transmitter,
road speed (L2)
54.8-550/l F 2
EXIT
EXIT
D. Engine 102.983
1st version up to approx. 30.06.86 (round rod)

Connecting rod (6) . . . . . . , . . . . . . . . . . . . . . . . . , Disengage at transfer lever
Throttle . . . , . , . . . . , . . . . . . . , . . . , , Move into idle speed position
control
Connecting rod (6). ...................... , Set approx. 1 mm or 1 turn shorter
Connecting rod (6). ...................... . Engage
Ball socket (3). ......................... . Lock
2nd version starting approx. 01.07.86 (profiled rod)

Hex. head screw ........................ . Loosen on profiled rod (6)
Throttle control ........................ , Move into idle speed position
Lever of actuator ........................ . Lift approx. 1 mm from idle speed position
Hex. head screw ........................ . Tighten in this position
54.8-56114 F 2
EXIT
E. Engine 103
Air cleaner . . . . . . . , . . . . , . . . . . . . . . . . . . . . . . Remove

Connecting rod (1). . . . . . . . . * . . . . . . * . . . . . Disengage at throttle control
Throttle control . . . . . . . . . . . . . . . . . . . . . . . Move into idle speed position
Lever of actuator (M16) . . . . . . . . . . . . . . . . . . Force into idle speed position with
connecting rod (1)
Connecting rod (1) ...... . . . . . . . . . . Adjust approx. 1 mm or 1 turn shorter
Connecting rod (1) . . . . . . . . . . . . . . . . . . . . . . Engage
Ball head (3).......... . . . * . . . , . . . . . . * . Lock
Air cleaner ........... , . . . . . . . . . . . . . . . Mount
54.8-56115 F 2
EXIT
F. Engines 601, 602.912 and 603.912
Connecting rod (1) .........................Disengage on actuator (M16)

Throttle control ..........................Move into idle speed position
Lever (2) of actuator (M16) ................... Force away from engine in idle speed position
Connecting rod (1). ........................Adjust approx. 0.5 mm or 1 turn shorter
Connecting rod (1) .........................Engage
54.8-56116 F 2
EXIT
G. Engine 602.961
Hex. head screw (4) ........................Loosen at profiled rod (1)

Throttle control .......................... Move into idle speed position
Lever of actuator (M 16). ..................... Force toward engine into idle speed position
Profiled rod (1) ........................... Adjust approx. 0.5 mm longer
Hex. head screw (4) ........................ Tighten in this position
54.8-56117 F 2
EXIT
B. Model 201
N4 N4
1542 -14540
I
N4 N4
Floor mat front right or left.................. Remove

Legrest. ............................... Remove
Connector of harness on control unit N4 ......... Pull off
Control unit N4. ......................... Unscrew from legrest (version A)
Fastening plate for control units ............... Remove (version B)
Control unit N4. ......................... Unscrew from fastening plate (version B)
A = 1 st version
B = 2nd version
54.8-56512 F 2
EXIT
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In vice-versa sequence. On defective control

unit be sure to check adjustment of
connecting rod (refer to Note)
Function test ............................ Perform on road
Note
A new control unit with coding plug is installed

on models 201.029/128. The other models are
phased-in.
The new control unit with coding plug has no

influence on wiring and thereby also not on
wiring diagrams.
54.8-56513 F 2
EXIT
54-566 Removal and installation of coding plug
Model 201
1543-1460911
N4f2
Floor mat front. ..........................Remove

Legrest ................................Remove
Coding plug (R29) . . . . . . . . . . . . . . . . . . . . . . . . . Pull from control unit (N4/2)
54.8-566/l F 2
EXIT
54-575 Removal and installation of switch on clutch pedal
I
s4011
1543-14610
Cover at left or right under

instrument panel ..........................Remove (68-l 50)
Connector of switch (S40/1) .................. Pull off
Switch (S40/1) ...........................Loosen and remove
54.8-57511 F 2
EXIT
54-579 Layout of plug connections
B. Model 201
x5/3 Plug connection interior/compressor harness

X33/2 or 3311 Plug connection CIS-E/cruise control 2-pole
54.8-579/3 F 2
EXIT
x5/1 Cable connector interior

x20 Plug connection stop lamp switch
X21/3 Cable connector stop lamp switch/cruise control/Tempomat 1 -pole
x33 Plug connection CIS-E/cruise control 1 -pole
x53/3 Plug connection Hall sensor/EGR 1 -pole
x53/4 Plug connection inductive transmitter/EG R 2-pole
x53/5 Multiple plug connection/Hall sensor (only if stop lamp signal is required for several special requests)
x91 Cable connector clutch pedal/cruise control 1 -pole
54.8-579/4 F 2
. . ........ ..... EXIT
.... ....................................
(THIS PAGE INPENTIONALLY LEFT BLANK)

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EXIT

Ground connecting points

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................... 54-500

54-005 Battery test, service and maintenance

Visual checkup for external leaks

Check acid level should reach up to mark.

Battery state of charge Climatic condition Density at 20 OC Procedure

charged normal 1.28)

half charged normal 1.20 recharging

discharged normal 1.12 recharge

*) Tolerance * 0.01 kg/dm3

Example for defective batteries

a) Acid density in one cell deviates noticeable in downward

I-1,28 1 I,202 1,283. 1,284 l,lfis 1,286

b) Acid density deviates in two adjacent cells (e.g. 2 and 3)

Condition: Leak in cell wall between

Testing battery under load This test is possible only at uniform

Positive pole (+I of battery to positive pole of charger,

negative pole (-1 of battery to negative pole of charger.

C. Handling battery when laying up vehicle

Prerequisite: Battery state of charge in order

1. Disconnect negative terminal of battery.

This will prevent discharging by rest potential consumers or time clock.

Antifreeze in charged condition

D. Batteries with overfill protection

These batteries are provided with rubber diaphragm

When refilling with distilled water, make sure that

Checking fluid level and adding distilled water

On batteries with overfill protection the fluid level is

Refilling with distilled water

The distilled water flows through circularly located

When the fluid level is at max. mark it will L d 1542-8185

simultaneously close the vent ducts. As a result, the

2 Air cushion 1542-8180

Checking acid density

To check acid density, insert syphon through triple-

Initial filling of battery with acid

During initial filling with acid insert the filling device

Note: If a battery with overfill protection is scrapped,

54-100 Designation and layout of ground connecting points

Layout: Main ground, behind instrument cluster.

1 Ground for central electrics

Layout: Ground, front right at lamp unit.

Layout: Ground, wheelhouse front left at

Layout: Ground above engine (instrument

Layout: Ground, trunk on wheelhouse, left.

Layout: Ground, trunk at the right near tail

Layout: Ground, front left at lamp unit.

Lefthand steering vehicle

Layout: Ground, battery

Righthand steering vehicle

Layout: Ground, battery

54-140 Central electrics

The central electric system comprises the following

- Double contact with relay air conditioning

The central electric system permits subdivision of main

- Harness for rotary light switch

- Harness for headlamp, left

- Harness for headlamp, right etc.

The individual harnesses are connected to central

The cast in switchplate connects the individual

Feeding of terminal 30 proceeds on face of central

B. Association of harness couplings to coupling fields

Interior H Vacant P Relay overvoltage protection

) Tolerance 0.01 kg/dm3